Is your wireless router robust enough to connect your critical infrastructure? Answer these 6 questions to be sure.
If you're looking for a reliable wireless router to connect and manage your mission-critical infrastructure, you need a purpose-built system that has proven reliable in the real world.
The router must be robust enough to ensure uninterrupted operation in very demanding environments - surviving exposure to extreme temperatures, humidity, vibration and fluctuating power conditions, and often located in remote, infrequently visited locations. A router designed for use in a data center will not survive in such conditions.
Narrowing your search to routers labeled for industrial use is a good place to start looking for good equipment, but the specifications on the product sheet don't always tell the whole story. Manufacturers in some countries (including the United States and Canada), operate on a self-certification basis. This means that manufacturers self-certify and certify compliance with certain safety and reliability guidelines, which gives room for interpretation....
This lack of formal, standardized testing and certification of router robustness means it can be difficult to gain an accurate understanding of what you're buying. It's important to go beyond the specifications and dig a little deeper into the details of system design, reliability testing and certification compliance. The six questions listed here will reveal the information you need to make the best choice.
What is the housing made of?
Today's high-performance chipsets, especially those based on 5G and Wi-Fi 6, generate a lot of heat. This heat can cause products to malfunction and ultimately damage internal electronics, so it must be dissipated quickly and efficiently from the router.
Extruded aluminum enclosures are inexpensive and strong enough to pass basic drop tests, but are not good for heat management. Die-cast aluminum is a better choice because it can absorb and dissipate heat more efficiently. In addition, because die-cast aluminum is more flexible in terms of design, the enclosure can be designed with built-in heat sinks and heat seals, or with useful features such as grounding rings that make it easier to mount the router safely and securely.
Can the housing withstand exposure to environmental conditions?
Wireless routers installed in critical infrastructure and vehicles are routinely exposed to dust, dirt and liquids. Sealsaround the chassis and all ports must be tight enough to prevent foreign elements from entering the system and causing failure. The ability to withstand exposure to harmful substances is covered by the standardized for ingress protection (IP). The first digit in the standard IP rating indicates the level of protection against hazardous parts (wires, moving parts) and ingress of solid foreign objects.
The second digit indicates water protection. For environments where the router may be exposed to the elements, look for a rating of no less than IP64, which means the housing is dustproof and resistant to splashing water.
How does the router respond to low voltage?
Routers used in remote areas are oftenpowered by solar panels and batteries, exposing electronic equipment to voltage fluctuations that can interfere with operation. Routers used in vehicles are often exposed to low voltage when starting the vehicle. There are three important things to look for when evaluating router power.
Energy consumption
When using solar charging, the lower the power consumption, the higher the reliability. Solar panels and batteries can be smaller and more cost-effective if the router is very efficient.
In adverse conditions where power generation is limited, such as snow on a solar panel, any remaining available power will continue to be available, allowing for longer communication. Look for routers that consume less than 1 W in idle mode when connected to a 5G network.
Voltage range
The router needs to operate over a wide voltage range to withstand power fluctuations, especially in winter when hours with sunlight are short. For example, on a 12V system, the voltage can drop as low as 5V, so a device that can operate at such low voltages as 5-7VDC will ensure continuous operation during voltage drops. Starting voltage in vehicles can also drop very low.
Standby mode / Low voltage disconnection
A well-designed rugged router will offer a standby or lower power consumption mode. This allows the device to reduce its functionality and go into a very low power consumption mode - for example, a remote router can run for five minutes at the beginning of each hour to respond to hourly requests from a SCADA system. The standby mode can also be used to protect the battery from damage in adverse conditions by shutting down the router - for example, if the voltage drops below 10VDC, the router will not resume until 12VDC, allowing the solar panel to charge the battery without putting any additional load on the router.
How does the router perform in extreme temperature ranges?
A router mounted in an enclosed space or inside a vehicle can be exposed to the hottest summer days and coldest winter nights. If the router is mounted in an enclosed space, temperatures can be much higher than the ambient temperature. The router must perform as expected in all these conditions.
The operating temperature range specified for rugged environments is typically -30 to +70 °C. Problems can occur at the border of these ranges. The router may fail to start up, data rates may be significantly lower, radio output power may deteriorate, and key components may shut down. Some of these actions are acceptable because they help protect the router's circuitry, but they should only occur under extreme conditions that are beyond normal operating parameters.
Any finding of reduced performance or output power within a certain range is a red flag. Ensure that the router has been tested while operating at full capacity - for example, with data transmitted over a 5G radio, at high transmit power, while loading Ethernet ports at maximum speed - at both ends of the range and beyond.
Also note that temperature testing requires specialized equipment, such as thermal chambers and "call boxes" that simulate carrier networks in a laboratory. Make sure the router has been temperature tested in a formal, properly organized environment.
Can the router be used in hazardous environments?
If you operate in hazardous environments such as oil and gas production, midstream and downstream operations, cellular routers must be specially designed to minimize the risk of ignition. Routers, and all electronic equipment used in these locations, must be tested by an independent laboratory and certified safe for use in such environments. Look for routers certified to international standards, such as Class 1 Div 2 in North America or ATEX in Europe.
How does the manufacturer test the router?
In the world of rugged routers, durability and reliability are the primary measures of success. Top manufacturers conduct Accelerated Life Testing (ALT), a rigorous process that simulates more than seven years of product wear and tear. These tests replicate the harsh conditions and high-stress scenarios that routers can potentially encounter over their lifetime, including extreme temperatures, vibration and power fluctuations. This is critical to ensuring quality and reliability over time.
Take the next step
To learn more about routers for special tasks contact us. We'll match you with the right solution and find the right equipment for your needs, even if special task equipment is required.
Here's a checklist of what to look for when evaluating an enhanced router:
- Housing made of die-cast aluminum
- Housing with at least IP64 protection
- Power supply with a power consumption of less than 1 W in idle mode, a voltage range with a low end of 5-7 VDC, and a standby or low voltage disconnect mode
- Operating temperature range from -30 to +70°C, with verified full capacity operation at both ends of the range
- Certified Class 1 Div 2 for safe operation in environments where
Flammable vapors or gases are used in closed containers or closed systems
- Accelerated Life Testing (ALT) to ensure product quality and reliability for the life of the product.
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